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Ok, I've got the new steel gear. Got the roll pin out, whats the secret to getting the gear off? Heat? I'm guessing getting the new one on (and lined up with hole for pin) will be tough also.
I would put the old gear in a vise and hammer in the center maybe. Or if you had acces to a press, not sure if the gears are a press fit or not, i've never had to replace one.
Use a puller, a simple 2 jaw will do the trick. To put it back on you can use a socket and hammer with the shaft resting on something solid like a vise, surprisingly aligning the hole never seems to be a big problem.. or at least not for me.
If it's not too late, a reman'd distributor (with core exchange) might be a better option. I went with a roller cam swap and the reman'd dizzy. with a steel gear, was roughly 10 bucks more that buying the gear alone Aligning the holes is a crap shoot; sometimes they line up, sometimes they don't.
I am trying to change out mine tonight as well, I am running an 88 5.0, but yanked off the EFI in favor of a carb. I have the distributor that came with the carb set up, but am wondering what depth to set the gear at now? Set it at the same place as the carbed one is or something different. I found a Ford link that freaked me out saying you need to do this and that or you could set it too deep and hurt your block. Is this true? Should I just set it at the same level as the carbed distributor even though I am still using the EFI camshaft? sorry too long post